Ball bat including a fiber composite barrel having an accelerated break-in fuse region

ABSTRACT

A ball bat extending about a longitudinal axis and configured for testing under an accelerated break-in test. The bat includes a barrel portion including a proximal region and a distal region. The barrel portion is formed of a fiber composite material having wall thickness of at least 0.100 inch. The fiber composite material includes at least first and second plies. The first ply includes a first plurality of fibers aligned adjacent to one another and a first resin, and the second ply includes a second plurality of fibers aligned adjacent to one another and a second resin. The first ply includes a first fiber discontinuity and the second ply includes a second fiber discontinuity. The first and second fiber discontinuities are generally aligned with each other such that one of the first and second fiber discontinuities substantially overlies the other of the first and second fiber discontinuities creating an ABI fuse region of the barrel portion. The ABI fuse region forms a crack initiation location when the bat is subjected to the accelerated break-in test.

FIELD OF THE INVENTION

The present invention relates to a ball bat including a fiber compositebarrel portion having an accelerated break-in (ABI) fuse region.

BACKGROUND OF THE INVENTION

Baseball and softball organizations periodically publish and updateequipment standards and/or requirements including performancelimitations for ball bats. One recently issued standard is the Bat-BallCoefficient of Restitution (“BBCOR”) Standard adopted by the NationalCollegiate Athletic Association (“NCAA”) on May 21, 2009. The BBCORStandard, which became effective on Jan. 1, 2011 for NCAA baseball, is aprincipal part of the NCAA's effort, using available scientific data, tomaintain as nearly as possible wood-like baseball bat performance innon-wood baseball bats. Although wood ball bats provide many beneficialfeatures, they are prone to failure, and because wooden ball bats aretypically solid (not hollow), wooden bats can be too heavy for youngerplayers even at reduced bat lengths. Wood ball bats also provide littleor no flexibility in the design of the hitting or barrel region of thebat. Non-wood bats, such as bats formed of aluminum, other alloys,composite fiber materials, thermoplastic materials and combinationsthereof, allow for performance of the bat to be more readily tuned oradjusted throughout or along the hitting or barrel portion. Suchcharacteristics enable non-wood bats to provide more consistentperformance, increased reliability and increased durability than woodbats.

Other organizations have also adopted the BBCOR Standard. For example,the National Federation of State High School Associations (NFHS) has setJan. 1, 2012 as the effective date for implementation of the BBCORStandard for high school play. The BBCOR Standard includes a 0.500 BBCORbat performance limit, which specifies that no point on the barrel orhitting portion of a bat can exceed the 0.500 BBCOR bat performancelimit.

Another recent example of new bat performance limitations is the new USABaseball bat standard (USABat) which also includes accelerated break-intesting of composite ball bats to ensure that the bat's performance doesincrease during or after undergoing a bat rolling procedure. Effectiveon Jan. 1, 2018, Little League Baseball® will adhere to the new USABatstandard, and no bats previously approved for use in Little League playwill be permitted to be used in any Little League game or practice, orother Little League event. Other organizations implementing the newUSABat standard include PONY Baseball, Babe Ruth Baseball/Cal RipkenBaseball, Dixie Youth Baseball, American Amateur Baseball Congress andAmateur Athletic Union.

When fiber composite bat barrels are used in a bat design, many of thenew equipment standards and/or requirements also require the bat toundergo an accelerated break-in test procedure wherein the bat isrepeatedly rolled in a barrel rolling procedure and then performancetested until the bat fails or shows evidence of failing.

Accordingly, a need exists to develop a method and/or system for formingbarrel portions of a ball bat or other cylindrical portions of a ballbat using fiber composite material that can satisfy ball bat equipmentstandards and/or requirements in a cost effective, reliable and highquality manner. What is needed is a system or process of developing aball bat that provides a high quality cosmetic appearance, is highlydurable, and provides the desired operational characteristics. It wouldbe advantageous to provide a ball bat, and a system or method forproducing a ball bat including a barrel portion formed of fibercomposite material, that can satisfy performance requirements, such asBBCOR certification or the USABat standard, without adding too muchweight or wall thickness to the barrel portion. It would be advantageousto provide a ball bat with a desirable level of barrel stiffness, andprovides exceptional feel and performance.

SUMMARY OF THE INVENTION

The present invention provides a ball bat extending about a longitudinalaxis and that is configured for testing under an accelerated break-intest. The bat includes a barrel portion including a proximal region anda distal region. The barrel portion is formed of a fiber compositematerial having wall thickness of at least 0.100 inch. The fibercomposite material includes at least first and second plies. The firstply includes a first plurality of fibers aligned adjacent to one anotherand a first resin, and the second ply includes a second plurality offibers aligned adjacent to one another and a second resin. The first plyincludes a first fiber discontinuity and the second ply includes asecond fiber discontinuity. The first and second fiber discontinuitiesare generally aligned with each other such that one of the first andsecond fiber discontinuities substantially overlies the other of thefirst and second fiber discontinuities creating an ABI fuse region ofthe barrel portion. The ABI fuse region forms a crack initiationlocation when the bat is subjected to the accelerated break-in test.

According to a principal aspect of a preferred form of the invention, aball bat extending about a longitudinal axis and that is configured fortesting under an accelerated break-in test. The bat includes a barrelportion that includes an inner surface and is formed of a fibercomposite material having wall thickness of at least 0.100 inch. Thefiber composite material includes at least first and second plies. Thefirst ply includes a first plurality of fibers aligned adjacent to oneanother and a first resin, and the second ply includes a secondplurality of fibers aligned adjacent to one another and a second resin.The inner surface of the barrel portion defines at least one annulargroove. The at least one annular groove creates an ABI fuse region ofthe barrel portion. The ABI fuse region forms a crack initiationlocation when the bat is subjected to the accelerated break-in test.

This invention will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingdrawings described herein below, and wherein like reference numeralsrefer to like parts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a ball bat in accordance with oneimplementation of the present invention.

FIG. 2 is a side perspective view of a barrel portion of the ball bat ofFIG. 1 including a sectional view of the wall of the barrel portion.

FIG. 3A is an enlarged view of a section of the wall of the barrelportion of the ball bat taken at circle 3 of FIG. 2.

FIGS. 3B through 3E are enlarged views of a section of a wall of abarrel portion of a ball bat taken at circle 3 of FIG. 2 in accordancewith other example implementations of the present invention.

FIGS. 4A through 4C are side views illustrating example implementationsof a plurality of layers of fiber composite material prior to wrappingaround a bladder and mandrel in accordance with other implementations ofthe present invention.

FIG. 5A is a top perspective view of a portion of two representativeplies of fiber composite material spaced apart from each other inaccordance with another example implementation of the present invention.

FIG. 5B is a top perspective view of a portion of two representativeplies of fiber composite material spaced apart from each other inaccordance with another example implementation of the present invention.

FIG. 6 is an enlarged sectional view of six outer plies of a fibercomposite material of a primary tubular region of a barrel portion.

FIG. 7 is a representation of a bat rolling procedure on a ball bat andis a reproduction of FIG. 1 of the NCAA Standard for Testing BaseballBat Performance, Bat-Ball Coefficient of Restitution.

FIG. 8 is a side view of a ball bat in accordance with anotherimplementation of the present invention.

FIG. 9 is a side view of a ball bat in accordance with anotherimplementation of the present invention.

FIG. 10A is a top, side perspective view of an annular stiffeningelement in accordance with an example implementation of the presentinvention.

FIG. 10B is a cross-sectional view of the annular stiffening element ofFIG. 10A.

FIGS. 10C and 10D are cross-sectional views of annular stiffeningelements in accordance with other example embodiments of the presentinvention.

FIG. 10E is a cross-sectional view of a polygonal shaped stiffeningelement and a barrel portion of a bat in accordance with another exampleimplementation of the present invention.

FIG. 11A is a top, side perspective view of a disc stiffening element inaccordance with an example implementation of the present invention.

FIG. 11B is a side perspective view of a disc stiffening element inaccordance with another example implementation of the present invention.

FIG. 11C is a top, side perspective view of a disc stiffening element inaccordance with another example implementation of the present invention.

FIGS. 11D through 11F are top, side perspective views of disc stiffeningelements in accordance with other example implementations of the presentinvention.

FIG. 12 is a longitudinal cross-sectional view of a portion of a batbarrel including an annular stiffening element in accordance with anexample implementation of the present invention.

FIGS. 13A and 13B are longitudinal cross-sectional views of portions ofbat barrels including disc stiffening elements in accordance with otherexample implementations of the present invention.

FIGS. 14A and B are longitudinal cross-sectional views of portions ofbat barrels including disc stiffening elements in accordance with otherexample implementations of the present invention.

FIG. 15 is a longitudinal cross-sectional view of a barrel portion of abat including an example ABI fuse region in accordance with an exampleimplementation of the present invention.

FIG. 16 is a longitudinal cross-sectional view of a portion of a batbarrel including an ABI fuse region in accordance with another exampleimplementation of the present invention.

FIGS. 17 through 21B are longitudinal cross-sectional views of portionsof bat barrels including ABI fuse regions in accordance with otherexample implementations of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a ball bat is generally indicated at 10. The ballbat 10 of FIG. 1 is configured as a baseball bat; however, the inventioncan also be formed as a slow pitch softball bat, a fastpitch softballbat, a rubber ball bat, or other form of ball bat. The bat 10 includes aframe 12 extending along a longitudinal axis 14. The tubular frame 12can be sized to meet the needs of a specific player, a specificapplication, or any other related need. The frame 12 can be sized in avariety of different weights, lengths and diameters to meet such needs.For example, the weight of the frame 12 can be formed within the rangeof 15 ounces to 36 ounces, the length of the frame can be formed withinthe range of 24 to 36 inches, and the maximum diameter of the barrelportion 18 can range from 1.5 to 3.5 inches.

The frame 12 has a relatively small diameter handle portion 16, arelatively larger diameter barrel portion 18 (also referred as a hittingor impact portion), and an intermediate tapered region 20. Theintermediate tapered region 20 can be formed by the handle portion 16,the barrel portion 18 or a combination thereof. In one preferredembodiment, the handle and barrel portions 16 and 18 of the frame 12 canbe formed as separate structures, which are connected or coupledtogether. This multi-piece frame construction enables the handle portion16 to be formed of one material, and the barrel portion 18 to be formedof a second, different material (or two or more different materials). Inother implementations, such as shown in FIG. 8, the bat can be formedwith a one-piece frame in which the handle portion, the intermediatetapered region and the barrel portion are one integral piece and theportions cannot be separated without destroying the frame.

Referring to FIG. 1, the handle portion 16 is an elongate structurehaving a proximal end region 22 and a distal end region 24, whichextends along, and diverges outwardly from, the axis 14 to form asubstantially frusto-conical shape for connecting or coupling to thebarrel portion 18. Preferably, the handle portion 16 is sized forgripping by the user and includes a grip 26, which is wrapped around andextends longitudinally along the handle portion 16, and a knob 28connected to the proximal end 22 of the handle portion 16. The handleportion 16 is formed of a strong, generally flexible, lightweightmaterial, preferably a fiber composite material. Alternatively, thehandle portion 16 can be formed of other materials such as an aluminumalloy, a titanium alloy, steel, other alloys, a thermoplastic material,a thermoset material, wood or combinations thereof.

Referring to FIGS. 1 and 2, the barrel portion 18 of the frame 12 is“tubular,” “generally tubular,” or “substantially tubular,” each ofthese terms is intended to encompass softball style bats having asubstantially cylindrical impact (or “barrel”) portion as well asbaseball style bats having barrel portions with generally frusto-conicalcharacteristics in some locations. The barrel portion 18 extends alongthe axis 14 and has an inner surface 30, an outer surface 40, a distalend region 32, a proximal end region 34, and a central region 36disposed between the distal and proximal end regions 32 and 34. Theproximal end region 34 converges toward the axis 14 in a directiontoward the proximal end of the barrel portion 18 to form afrusto-conical shape that is complementary to the shape of the distalend region 24 of the handle portion 16. The barrel portion 18 can bedirectly connected to the handle portion 16. The connection can involvea portion, or substantially all, of the distal end region 24 or taperedregion 20 of the handle portion 16 and the proximal end region 34 of thebarrel portion 18. In another implementation, the handle portion 16 canbe a tubular body having a generally uniform diameter along its lengthand an intermediate member can be fixedly attached to the distal endregion 24 for coupling the handle portion 16 to the barrel portion 18.The intermediate member can be used to space apart and/or attach thehandle portion 16 to the barrel portion 18. The intermediate member canspace apart all or a portion of the barrel portion 16 from the handleportion 16, and it can be formed of an elastomeric material, an epoxy,an adhesive, a plastic or any conventional spacer material. The bat 10further includes an end cap 38 attached to the distal end 32 of thebarrel portion 18 to substantially enclose the distal end 32.

The handle and barrel portions 16 and 18 can be coated and/or paintedwith one or more layers of paint, clear coat, inks, coatings, primers,and other conventional outer surface coatings. The outer surface 40 ofthe barrel portion 18 and/or the handle portion 16 can also includealpha numeric and/or graphical indicia 42 indicative of designs,trademarks, graphics, specifications, certifications, instructions,warnings and/or markings. Indicia 42 can be a trademark that is appliedas a decal, as a screening or through other conventional means.

The barrel portion 18 includes a primary tubular ball impact region 44that defines the region of the barrel portion 18 that is commonly orpreferably used for impacting a ball during use. The ball impact region44 includes the center of percussion (“COP”) of the ball bat 10. The COPis typically identified in accordance with ASTM Standard F2219-09,Standard Test Methods for Measuring High-Speed Bat Performance,published in September 2009. The COP is also known as the center ofoscillation or the length of a simple pendulum with the same period as aphysical pendulum as in a bat oscillating on a pivot. In oneimplementation, the ball impact region 44 includes the center ofpercussion and an area plus and minus three inches from the center ofpercussion. In other implementations, the ball impact region 44 can haveother lengths with respect to the longitudinal axis 14. The length ofthe ball impact region 44 is at least one inch, and can be positioned atany location along, or extend the entire length of, the barrel portion18.

The barrel portion 18 is preferably formed of strong, durable andresilient material, such as, a fiber composite material. In alternativepreferred embodiments, the barrel portion 18 can be formed of one ormore fiber composite materials in combination with one or more of analuminum alloy, a titanium alloy, a scandium alloy, steel, other alloys,a thermoplastic material, a thermoset material, and/or wood. In oneimplementation, the barrel portion 18 can be formed of a fiber compositematerial having wall thickness of at least 0.060 inch.

Referring to FIGS. 2, 3A, 4A, 5 and 6, a fiber composite material ispreferably used to form at least a portion of the barrel portion 18. Asused herein, the terms “composite material” or “fiber compositematerial” refer to a matrix or a series of plies 50 (also referred to assheets or layers) of fiber bundles 52 impregnated (or permeatedthroughout) with a resin 54. Referring to FIGS. 4A, 5 and 6, the fiberbundles 52 can be co-axially bundled and aligned in the plies 50.

A single ply 50 typically includes hundreds or thousands of fiberbundles 52 that are initially arranged to extend coaxially and parallelwith each other through the resin 54 that is initially uncured. Each ofthe fiber bundles 52 includes a plurality of fibers 56. The fibers 56are formed of a high tensile strength material such as carbon.Alternatively, the fibers can be formed of other materials such as, forexample, glass, graphite, boron, basalt, carrot, Kevlar®, Spectra®,poly-para-phenylene-2, 6-benzobisoxazole (PBO), hemp and combinationsthereof. In one set of preferred embodiments, the resin 54 is preferablya thermosetting resin such as epoxy or polyester resins. The resin 54can be formed of the same material from one ply to another ply.Alternatively, each ply can use a different resin formulation. Duringheating and curing, the resin 54 can flow between plies 50 and withinthe fiber bundles 52. The plies 50 preferably typically have a thicknesswithin the range of 0.002 to 0.015 inch. In a particularly preferredembodiment, the ply 50 can have a thickness within the range of 0.005 to0.006 in. In other alternative preferred embodiments, other thicknessranges can also be used.

The plies 50 are originally formed in flexible sheets or layers. In thisconfiguration, the fibers 56 and the fiber bundles 52 are arranged andaligned such that the fibers 56 generally extend coaxially with respectto each other and are generally parallel to one another. As the ply 50is wrapped or formed about a bladder 58 and mandrel, or other formingstructure, the ply 50 is shaped to follow the form or follow the shapeof the bladder 58 and mandrel. Accordingly, the fiber bundles 52 andfibers 56 also wrap around or follow the shape of the bladder 58 orother forming structure. In this formed position or state, the ply 50 isno longer in a flat sheet so the fiber bundles 52 and fibers 56 nolonger follow or define generally parallel lines. Rather, the fiberbundles 52 and fibers 56 are adjacent to one another, and are curved orotherwise formed so that they follow substantially the same adjacentpaths. For example, if a ply 50 is wrapped about the bladder 58, the ply50 can take a generally cylindrical or tubular shape and the fiberbundles 52 and fibers 56 can follow the same cylindrical path or definea helical path (depending upon their angle within the ply 50). Thefibers 56 remain adjacent to one another, are aligned with each otherand follow substantially similar paths that are essentially parallel (oreven co-axial) for example, when viewed in a sectional view in a singleplane or other small finite segment of the ply 50.

The fibers 56 or fiber bundles 52 are preferably formed such that theyextend along the ply 50 and form generally the same angle with respectto an axis, such as the axis 14. The plies 50 are typically identified,at least in part, by the size and polarity of the angle defined by thefibers 56 or fiber bundles 52 with respect to an axis. Examples of suchdescriptions of the plies 50 can be fibers 56 or fiber bundles 52defining a positive 30 degree angle, a negative 30 degree angle, apositive 45 degree angle, a negative 45 degree angle, a positive 60degree angle, a negative 60 degree angle, a positive 70 degree angle, anegative 70 degree angle, a positive 80 degree angle, a negative 80degree angle, a 90 degree angle (extending perpendicular to the axis14), and a 0 degree angle (or extending parallel to the axis 14). Otherpositive or negative angles can also be used. Accordingly, in thepresent application, a single ply 50 refers to a single layer of fibercomposite material in which the fiber bundles 52 extend in substantiallythe same direction with respect to a longitudinal axis along the singlelayer, such as plus or positive 45 degrees or minus or negative 60degrees.

Fiber composite material used to form at least a portion of the handleor barrel portions 16 or 18 of the bat 10 typically includes numerousplies 50. The number of plies 50 used to form a barrel portion 18 can bewithin the range of 3 to 60. In a preferred embodiment, the number ofplies 50 used to form the barrel portion 18, or a primary tubular regionthereof, is at least 10 plies. In an alternative preferred embodiment,the number of plies 50 used to form the barrel portion 18, or a primarytubular region thereof, is at least 20 plies. In other implementations,other numbers of plies can be used.

Referring to FIG. 5, fiber composite materials typically are formed orlaid-up using pairs of plies 50 having fiber bundles 52 extending inopposite angular polarities. For example, a ply 50 a formed of fiberbundles 52 and fibers 56 generally extending at a positive 45 degreeangle (also referred to as a plus 45 degree ply) will be paired with asecond ply 50 b that is formed with fiber bundles 52 and fibers 56generally extending at a negative 45 degree angle (also referred to as anegative 45 degree ply). This pattern typically extends throughout afiber composite material. The alternating angular arrangement of thefiber bundles 52 and fibers 56 is important to achieving and maintainingthe structural integrity of the component or structure being formed ofthe fiber composite material. The overlapped region of the two plies 50a and 50 b can be essential for ensuring that, once cured, the fibercomposite material has the desired strength, durability, toughnessand/or reliability. The transition between alternating pairs of plies 50can also support the structural integrity of the composite structure.For example, a series of six plies could include a pair of plus andminus 30 degree plies, followed by a pair of plus and minus 45 degreeplies, followed by another pair of plus and minus 30 degree plies. Thetransition from the minus 30 degree ply to the adjacent plus 45 degreeply also provides added structural integrity to the fiber compositematerial because an overlapped region, such as region 60, still existsfrom one ply to an adjacent ply. In other implementations, pairs ofplies 50 having opposite polarities but differing fiber angles can beused. In still other implementations, two or more plies can be of thesame polarity, such as disclosed by U.S. Pat. Nos. 8,858,373 and8,852,037.

Handle and barrel portions 16 and 18 formed of fiber composite materialcan include several layers of plus and minus angular plies of differentvalues, such as, for example, plus and minus 30 degree plies, plus andminus 45 degree plies, plus and minus 60 degree plies. One or morelayers of 0 degree plies, or 90 degree plies can also be used. Referringto FIG. 6, the plies 50 may be separated at least partially by one ormore scrims 66 or veils. The scrim 66 can be used to enable independentmovement of the plies 50 above and below the scrim 66 during use afterthe barrel portion 18 is molded and cured. The scrim 66 can also be usedto inhibit, stop or reduce resin flow from one ply 50 to another ply onthe opposite side of the scrim 66.

The composite material is typically wrapped about a mandrel that iscovered by a bladder 58, the bladder 58 and mandrel once wrapped withthe desired number of plies 50 of fiber composite materials is placedinto a mold, pressure is applied to the bladder, and the fiber compositematerial is molded and cured under heat and/or pressure to produce thebarrel portion 18 and/or a primary tubular region thereof. While curing,the resin is configured to flow and fully disperse and impregnate thematrix of fiber bundles 52. In alternative embodiments, one or more ofthe plies, sheet or layers of the composite material can be a braided orweaved sheets or layers. In other alternative preferred embodiments, theone or more plies or the entire fiber composite material can be amixture of chopped and randomly fibers dispersed in a resin.

Referring to FIG. 4A, one implementation of a lay-up of a barrel portion18 of a bat 10 can be seen. Separate plies 50 are shown, each havingseparate fiber angles and polarities. The plies 50 are shown asgenerally flat two-dimensional sheets prior to being placed or wrappedabout the bladder 58 positioned over a mandrel. The mandrel is formed ina shape that defines the inner volume of a tubular barrel portion uponthe completion of the molding and curing. The bladder 58, when placed inthe mold, is pressurized to exert a force or pressure onto the plies 50ensuring that the plies conform to the shape of the mold and achieveproper compaction, and the desired wall thickness, etc. For example, thebladder can be pressurized to 150 psi. In other molding operations,other pressure values can be used. The bladder 58 and mandrel can beformed of any material that maintains its shape and integrity during thecuring process, such as a polyurethane bladder over a wooden mandrel.Once the bladder 58 is in position, the process of “laying up” the plies50, or layers, comprising the fiber composite material can be performed.The shape and overall size of the plies 50 can vary from one to another.Each ply can be sized to extend about all or a portion of the underlyingbladder 58/mandrel or the underlying ply 50. Preferably, the ply 50 issized to extend or wrap around the entire or full circumference of thebladder and about the axis 14. A plurality of uncured plies 50 of fibercomposite material can be wrapped or otherwise applied about the bladder58.

Once the lay-up of the desired number of plies 50 is completed, thebladder 58 and mandrel with the wrapped composite layers or plies areplaced into a mold, the bladder is pressurized, the mold is heated toform (mold and cure) the barrel portion 18. After curing, the bladder 58and the mandrel can be removed from the inner surface of the barrelportion 18 through conventional means, such as, for example, extractionor heating.

In some applications, it is desirable to produce a barrel portion formedof fiber composite material having high angle fibers (fiber compositematerial having fiber angles of 45 degrees or greater). The use of highfiber angles for the production of unidirectional fiber compositecomponents, including a barrel portion or cylindrical portions of abarrel portion, can be desirable because the stiffness of the barrelportion, or a primary tubular region thereof, can be greatly increasedwithout adding to the weight or the wall thickness of the barrelportion.

Referring to FIG. 4A, in one implementation a ply 70 represents theinnermost ply 50 or layer applied to the bladder 58, a ply 72 ispositioned over ply 70. In one preferred method of laying up the barrelportion 18, the plies 70 and 72 can be initially laid over each otherand then wrapped over about the barrel portion as a pair of plies havingopposite polarities. In other preferred methods, a single ply or threeor more plies can be applied or wrapped about the bladder/mandrel as asingle ply layer or a triple or higher ply layer. Plies 74 through 84illustrate one potential lay-up of layers to a bladder/mandrel. Each ofthe plies 74 through 84 includes fibers angled with respect to thelongitudinal axis 14. In the example implementation of FIG. 4A, theplies 70 through 84 include fibers angled with respect to thelongitudinal axis by +45 degrees, −45 degrees, +30 degrees, −30 degrees,+60 degrees, −60 degrees, +45 degrees and −45 degrees, respectively.However, in other implementations, other numbers of angled plies can beused in the lay-up, laminate or wall thickness of the molded barrelportion 18 or primary tubular region thereof.

As discussed in the Background, many existing and new equipmentstandards and/or requirements require bats that include a barrel formedof a composite material to undergo an accelerated break-in testprocedure wherein the bat is repeatedly rolled in a barrel rollingprocedure and then performance tested to measure the peak BBCOR of thebat until the bat fails or shows evidence of failing. One example is theNCAA's Bat-Ball Coefficient of Restitution (BBCOR) testing protocol,updated on Aug. 1, 2016, which requires the measurement of barrelcompression in accordance with ASTM F2844 and then the rolling of thebat using a barrel rolling procedure.

The barrel rolling procedure requires a bat rolling apparatus thatincludes two wheels, a fixture for pressing the wheels into the batbarrel in increments up to 0.012 inch, and a device to roll the barrel.The wheels are formed of a durable material such as nylon and have adiameter within the range of 1.5 to 3.0 inches. Following rolling of thebat, the BBCOR is measured using a bat test procedure. The bat rollingand bat performance testing is continued until the bat fails or exhibitsa decrease of BBCOR value by more than 0.018 from the maximum value. Thebarrel of the bat is placed into the fixture and marked with a 0 degreeorientation as identified in ASTM F2844. As shown in FIG. 7, the rollersare brought into contact with the barrel. The rollers are then displacedapproximately 0.050 in for the initial rolling. For subsequent rolling,the displacement is increased by up to 0.012 inch. The barrel is rolledto within 2.0 to 2.5 in of the endcap and past the taper (or area of nocontact between the rollers and the bat). The bat is rolledapproximately 10 times in each direction. The bat is then unloaded. Thebat is then clocked (or rotated) 45 degrees about its longitudinal axis,and the bat rolling steps are repeated. The bat rolling is repeatedagain after clocking the bat to 90 degrees and 135 degrees from itsoriginal position. The barrel compression is then re-measured using ASTMF2844. The rollers are displaced and the bat rolling steps are repeateduntil the barrel compression from rolling decreases by 5 percent.

The 2018 USABat standard also requires performance of an acceleratedbreak-in procedure including a bat rolling procedure. When performingABI tests, in order for a bat with a composite barrel to pass the test,the composite barrel bats must either fail (break) at some point duringthe test or show evidence of failing, cracking or crack initiation(depending upon the particular bat standard).

The present invention includes bat configurations, bat constructions andbat manufacturing methods that result in a ball bat with a compositebarrel that performs well and includes a predictable and engineeredfailure area or ABI fuse region. The ABI fuse region enables the batwith the composite barrel to pass applicable bat standards which includeABI testing requirements and also provide a region that indicateswhether the bat has been tampered with (by a bat doctor or the like) orwhether the bat has passed its useful life.

The present invention involves introducing a discontinuity in a locationon the bat barrel which can cause or result in a catastrophic failure ofthe bat barrel when the barrel is subjected to the rolling portion of anABI test.

FIG. 3A illustrates one example implementation of a barrel portion 18 ofa bat formed of fiber composite material that includes an ABI fuseregion 90. The ABI fuse region 90 relates to a bat composition and/orstructure that enables the bat to perform during normal or intended use,but fail or show indications of failure when subjected to an acceleratedbreak-in (ABI) test or procedure including a bat rolling procedure.Prior to laying up the composite plies 50 onto a bladder/mandrel 58 andthen curing the laid-up or “stacked-up” structure, the individual plies50 (or layers or flags) of composite material are cut or sliced into twopieces forming a cut or discontinuity 92 in the ply 50. The cutting orslicing of the ply 50 creates a discontinuity in the fibers making upthe ply 50. The cut 92 or slice can be applied to one or more plies 50in the stack-up, and the cuts 92 or slices are generally aligned witheach other such that at least a portion of the cut 92 or slice of oneply 50 overlies the cut 92 or slice of a second ply or more plies. Inone implementation the cuts 92 or slices aligned so that the cuts 92overlie each other within a longitudinal discontinuity dimension, d,within the range of 0 to 0.1 inch. In other implementations, thelongitudinal discontinuity dimension, d, can be within the range of 0 to0.25 inch.

In the example embodiment of FIG. 3A, a total of 16 plies 50 areillustrated in the barrel portion 18 or the wall thickness of the barrelportion 18. The barrel portion 18 of FIG. 3A is shown in a finalmanufactured state after the composite plies have been laid up about thebladder/mandrel 58, placed under heat and/or pressure and cured. Duringthe composite molding and curing process, the viscosity of the resindecreases such that the resin 54 flows throughout the ply 50 and otheradjacent plies 50. Accordingly, the cuts 92 are made prior to wrapping,laying up and curing the plies 50, once cured the cuts 92 are present inthe fibers 52 but the resin 54 has flowed to fill the space or voidcreated by the cuts 92. The cuts 92 are shown in 6 separate plies 50 ofan example stack up of 16 plies 50. The outermost plies 50 a, 50 b, 50 cand 50 d each include a cut 92. The next set of four plies 50 e, 50 f,50 g and 50 h are formed without a cut or a discontinuity. The next twoplies 50 i and 50 j include a cut 92. The cuts 92 formed in plies 50 a,50 b, 50 c, 50 d, 50 i and 50 j are all generally aligned with eachother such that the cuts 92 or discontinuities substantially overlieeach other within the longitudinal discontinuity dimension d.

Referring to FIGS. 3B through 3E, other example implementations of cuts92 placed into plies 50 of a laid-up structure forming the barrelportion 18 of the bat 10 are illustrated. The number of plies 50 thatinclude cuts 92 can vary in the composite structure. The position andspacing of the cuts 92 in the composite structure and between the plies50 can also vary. The size of the longitudinal discontinuity dimension,d, forming the ABI fuse region 90 can also vary. Still further, theangle of cuts 92 can be varied. In some implementations, the cuts 92 aresubstantially perpendicular to the longitudinal axis 14 of the bat 10.In other implementations, the cuts 92 can be angled from 30 to 89degrees from the longitudinal axis 14. FIG. 3B illustrates the compositebarrel portion 18 having 8 plies with cuts 92, the 8 plies are stackeddirectly upon each other, and our positioned toward the inner surface 30of the barrel portion 18. The longitudinal discontinuity dimension d isless than 0.1 inch. FIG. 3C illustrates an example implementation wherethe cuts 92 are in 8 plies 50 that are arranged in spaced apart pairs ofplies 50 throughout the lay-up of the barrel portion 18. Thelongitudinal discontinuity dimension d is less than 0.025 inch. FIG. 3Dillustrates another example implementation where the cuts 92 are in 7plies 50 that are arranged in generally random order throughout theouter two thirds of the lay-up of the barrel portion 18. Thelongitudinal discontinuity dimension d is less than 0.02 inch. FIG. 3Eillustrates another example implementation where the cuts 92 are in the7 outermost plies 50 of the barrel portion 18. The cuts 92 are angledwith respect to the longitudinal axis 14. The longitudinal discontinuitydimension d is less than 0.25 inch.

Referring to FIGS. 4A through 4C, other example implementations of thepresent invention are illustrated. In FIGS. 4A through 4C, the plies 70through 84 are specific examples of plies 50 shown in the order in whichthey are laid up onto the bladder/mandrel 58. In FIG. 4A, the cuts 92are illustrated on four of the eight plies (plies 84, 82, 78 and 74).The plies 84, 82, 78 and 74 include cuts 92 that are made substantiallyperpendicular to the longitudinal axis 14 of the mandrel whichcorresponds to the longitudinal axis 14 of the bat. FIG. 4B illustratesan example implementation where the cuts 92 are angled with respect tothe longitudinal axis 14 by approximately 75 degrees. Plies 72, 76, 80and 84 include cuts 92.

FIG. 4C illustrates another example implementation, in which the four ofthe plies are formed of two flag segments and each flag segment caninclude a different fiber angle. For example, ply 80 can be formed byflag segments 80 a and 80 b which are arranged end to end to form adiscontinuity or cut 92. Flag segment 80 a includes fibers generallyextending at an angle of minus 60 degrees with respect to thelongitudinal axis 14, and flag segment 80 b includes fibers generallyextending at angle of plus 30 degrees with respect to the longitudinalaxis 14. In ply 80, the discontinuity or cut 92 formed by the abuttingof the two flag segments 80 a and 80 b and the difference in fiber anglefrom flag segment 80 a and flag segment 80 b further contributes tolikelihood a crack initiation occurring at the ABI fuse region 90 duringa barrel rolling test of an ABI procedure. Plies 74, 76 and 78 are alsoformed by a pair of flag segments 74 a and 74 b, 76 a and 76 b, and 78 aand 78 b. As shown, the angles of the fibers can vary from one flagsegment to the next.

The barrel portion 18 including a proximal region 34 and a distal region32, and the barrel portion can be formed of a fiber composite materialincluding at least first and second plies. The first ply can be ply 80which can include the flag segment 80 a (or first proximal ply portion)and the flag segment 80 b (or first distal ply portion). The ABI fuseregion 90 is the first fiber discontinuity that separates the flagsegments 80 a and 80 b. The first plurality of fibers of the flagsegment 80 a are generally aligned to define first proximal angle withrespect to the longitudinal axis 14, and the first plurality of fibersof the flag segment 80 b are generally aligned to define first distalangle with respect to the longitudinal axis 14. In one implementation,the first proximal angle and the first distal angle can vary by at least10 degrees. In another implementation, the first proximal angle and thefirst distal angle can vary by at least 30 degrees.

Referring to FIGS. 5A and 6, in another example implementation of thepresent invention, the cut 92 can extend through only a portion of theply 50 and/or only through a portion of the fiber bundles 52. In FIGS.5A and 6, ply 50 has a thickness t and the cut 92 has a cut depth,d_(a), that is approximately 75 percent of the size of the thickness t.In another implementation the depth of the cut d_(c) can be at least 50percent of the thickness t of the ply 92. In one implementation, the cutdepth d_(c) is within the range of 33 to 100 percent of the plythickness t. In another implementation, the cut depth d_(c) is withinthe range of 50 to 100 percent of the ply thickness t.

When the cut depth d_(c) is less than 100 percent of the ply thicknesst, the ply 50 can be more readily positioned and handled during lay-upor stack-up of the composite structure, such as the barrel portion 18.Because the cut 92 is formed before the plies 50 are cured, a cut 92extending entirely through the ply 50 can make the ply more difficult tohandle and/or work with. Accordingly, in some implementations, the cuts92 are made at a cut depth that is less than the entire thickness of oneor more plies 50. Cuts 92 that do not extend entirely through the plythickness t still serve to create a discontinuity that can form an ABIfuse region.

Referring to FIG. 5B, another example implementation of a cut 92 ordiscontinuity is illustrated. The cut can also be formed as a pluralityof spaced apart cut segments 92 a that collectively represent the cut 92in ply 50 a. The spaced apart cut segments 92 a can extend entirelythrough the thickness t of the ply 50 or through a portion of thethickness t of the ply 50, also referred to as the depth of the cutd_(c), as shown in FIG. 5B. The length of each cut segment 92 a can bevaried. Additionally, the size of the distance between the cut segments92 a can also be varied. The spaced apart cut segments 92 a have asimilar effect of creating a discontinuity that can be used to form theABI fuse region 90. Adjacent plies, such as ply 50 b can include acontinuous cut 92. In other implementations, the adjacent plies, such asply 50 b, may also include spaced apart cut segments 92 a, or no cut 92.

FIGS. 3A through 6, illustrated example implementations of the presentinvention. However, other implementations are contemplated in thepresent invention. The number of plies 50 used to form the compositestructure such as the barrel portion 18 can be varied. The angles of thefibers within the plies 50 can be varied from ply to ply from one lay-upto another. The number of cuts 92 in a lay-up or stack-up can be variedfrom one application to another. The type of cuts 92 (the angle, depth,and length—segmented or non-segmented) can be varied. The depth d_(c) ofthe cut 92 of a ply 92 can also be varied from one ply to another ply.The use of flag segments to produce a ply can be used in one or more ofthe layers of a lay-up or stack up. The fiber angle of the fibers inadjacent flag segments can also be varied. The size of the longitudinaldiscontinuity dimension d can also be varied. The present inventionpresents a significant number of different implementations of fibers,fibers angles, cuts, cut angle, cut sizes, cut depths, etc. that resultin an almost infinite number of combinations available for producing anABI fuse region in a ball bat. Through use of these various cuts anddiscontinuities, a bat can be designed and customized for anyapplication. The present invention also enables a bat designer toproduce a bat with an ABI fuse region that will produce reliableconsistent results on the field and in certification or qualificationtesting.

Referring to FIGS. 8 and 9, in other implementations, a stiffeningelement 100 can be longitudinally positioned in barrel portion 18 of thebat 10 so as to be adjacent to the ABI fuse region 90 formed in theconstruction of the barrel portion 18. The stiffening element 100 cantake a variety of different forms, shapes, constructions, sizes, and/ormaterials. The stiffening element 100 serves to increase the compressivestrength, or the displacement compression, of the bat 10 at the axiallocation of the stiffening element 100 and at regions directly adjacentto the stiffening element 100. The effect of the stiffening element 100on the stiffness of the barrel portion 18 of the bat 10 can be shown byperforming a displacement compression test of softball and baseball batbarrels such as described in ASTM Std. No. F2844-11 with the stiffeningelement 100 installed and with the stiffening element 100 removed orabsent from the bat barrel portion 18. Using ASTM Std. No. F2844-11, oran equivalent test, a measure of the barrel compression BC of a bat canbe determined using a barrel compression test apparatus such as shown inFIG. 1 of ASTM Std. No. F2844-11.

In FIG. 8, a bat 10 formed with a separate handle portion 16 and barrelportion 18 is shown with the stiffening element 100 longitudinallypositioned adjacent the ABI fuse region 90 on the handle portion side ofthe ABI fuse region 90. In FIG. 9, a bat 200 formed of a one piece,integral bat frame 212 is shown in which the handle portion 16 iscontinuously and integrally formed with a tapered region 20 and thebarrel portion 18. The term one piece, integral bat frame means that thehandle portion 16 cannot be separated from the barrel portion 18 withoutdestroying or damaging one or both of the handle portion 16 or thebarrel portion 18. The bat 200 includes a stiffening element 100 that islongitudinally positioned within the barrel portion 18 of the bat 200 soas to be closer to the end cap 38 or distal end of the bat 200. FIGS. 8and 9 illustrate that the ABI fuse region 90 can be longitudinallypositioned on either side of the stiffening element 100. In otherimplementations, a bat can include two or more ABI fuse regions 90positioned on either side of a stiffening element 100, or two or morestiffening elements 100 positioned on either side of an ABI fuse region90.

In one implementation, the stiffening element 100 is longitudinallyspaced apart from the ABI fuse region 90 by a distance within the rangeof 0.1 to 1.0 inch. In other implementations, the stiffening element 100is longitudinally spaced apart from the ABI fuse region 90 by a distancewithin the range of 0.2 to 0.75 inch. In other implementations, thestiffening element 100 can be longitudinally spaced apart from the ABIfuse region 90 by other distances outside of these ranges. If an ABIfuse region 90 is placed on either side of the stiffening element 100,the distance from the stiffening element 100 to each of the ABI fuseregions can be the same or can be varied.

The placement of the stiffening element 100 adjacent to the ABI fuseregion 90 creates additional stress or loads upon the ABI fuse region 90such that when the bat is subjected to an accelerated break-in test thedifferential in barrel compression between the barrel portion 18 at thestiffening element 100 and the barrel compression of the barrel portionat the ABI fuse region facilitates failure or cracking of the barrelportion 18 at the ABI fuse region 90. The barrel compression of thebarrel portion 18 at the ABI fuse region 90 is lower than the barrelcompression of the barrel portion 18 at the location of the stiffeningelement 100 which accentuates or increases the stress placed upon thebarrel portion at or near the ABI fuse region 90 during the performanceof an ABI break-in test. The stiffening element 100 creates a suddenchange in barrel stiffness that can force a failure or catastrophicfailure of the bat barrel portion 18 during the bat rolling procedure ofthe ABI break-in test.

The stiffening element 100 can be any structure that stiffens the barrelportion 18 and increases the barrel compression value of the barrelportion 18 at the location of the stiffening element 100. The stiffeningelement 100 can be integrally formed with the barrel portion as shown inFIG. 14, or can be a separate component that is positioned within thebarrel portion 18. Accordingly, the stiffening element 100 can be moldedand cured with the barrel portion, it can be co-molded with the barrelportion, it can be press-fit within the barrel portion, it can beattached to the barrel portion using an adhesive, it can be coupled tothe barrel portion through an intermediate layer, or coupled in othermanners, or in any combination of the above-mentioned manners. Thestiffening element 100 can be an annular member that includes one ormore central openings (such as FIG. 10a ) or it can be a disc member(such as FIG. 11A) that provides a substantially uniform structureacross the hollow barrel portion 18. In another implementation, thestiffening element 100 can be a polygonal or irregular shaped structurethat is positioned within the barrel portion and includes at least 3points of contact between the stiffening element 100 and the innersurface 30 of the barrel portion 18. The stiffening element 100 ispreferably formed of a lightweight, rigid material such as aluminum orpolycarbonate. In other implementations, other materials can be usedsuch as other metals, other polymeric materials, wood, ceramic,elastomers, and combinations thereof.

Referring to FIGS. 10A and 10B, one example implementation of thestiffening element 100 is illustrated. The stiffening element 100 ofFIGS. 10A and 10B is annular member having an outer surface 102configured for engagement with the inner surface 30 of the barrelportion 18. In one implementation, the outer surface 102 can beroughened or include serrations 104 or other structure for increasingthe engagement with the barrel portion. In other implementations, theouter surface 102 of the stiffening element 100 can be generally smoothand attached to the inner surface 30 of the barrel portion 18 through apress-fit connection, an adhesive, thermal bonding, welding, otherconnection techniques or combinations thereof. The annular shape of thestiffening element 100 forms or defines an opening 106. Referring toFIG. 10B, the stiffening element 100 has a rectangular cross-sectionalshape. The thickness and length of the stiffening element 100 can bevaried to match a particular application or bat design.

Referring to FIGS. 10C and 10D, the stiffening element 100 can be formedin annular shape with different cross-sectional shapes. The stiffeningelement 100 of FIG. 10C has a generally L-shaped cross-sectional shapeand the stiffening element of FIG. 10D has a generally I-shapedcross-sectional shape. When the stiffening element 100 has anon-symmetrical cross-sectional shape, such as FIG. 10C, the stiffeningelement 100 can be installed within the barrel portion 18 of the bat 10with the thicker portion of the stiffening element 100 positioned closerto the handle portion 16 of the bat or closer to the end cap 38 of thebat as desired for a particular application or purpose. In otherimplementations, the stiffening element 100 can have an annular shapewith other cross-sectional shapes such as, for example, generallyU-shaped, generally T-shaped, generally V-shaped, square shaped,semi-circular, semi-ovular, other curved shapes and other polygonalshapes.

Referring to FIG. 10E, the stiffening element 100 may have an outersurface 102 that defines a polygonal shape such as an octagon. In otherimplementations, the stiffening element 100 can have outer shapes thatare triangular, square, pentagonal, hexagonal, or other polygonalshapes. The polygonal shaped stiffening element 100 engages the innersurface 30 of the barrel portion 18 at points or lines of contact 108.For example, the stiffening element of FIG. 10E has eight lines ofengagement or contact 108 with the inner surface 30 of the barrelportion 18. The polygonal shaped stiffening element 100 forms aplurality of gaps 110 between the outer surface 102 of the stiffeningelement 100 between the lines of engagement 108 and the inner surface 30of the barrel portion 18. The size and number of the gaps 110 can bevaried based upon a particular application. The stiffening element 100of FIG. 10E also includes cross-members 112 that extend through theopening 106. The cross-members 112 can cause the opening 106 to be aplurality of openings 106. The cross-members 112 can intersect thecenter of the stiffening element 100 and the longitudinal axis 14 of thebat, and can intersect each other. The cross-members 112 of FIG. 10Eintersect each other to form four separate openings 106 and four legsextending from the center of the stiffening element 100. Thecross-members 112 can have a thickness or width that matches the widthor thickness of the outer surface 102 of the stiffening element 100. Inother implementations, the cross-members 112 can have a thickness thatis less than the thickness of the outer surface 102. In otherimplementations, the cross-member 112 can take other shapes, forms,numbers, and/or sizes. The cross-members 112 may form 2 or more openings106 within the stiffening member 100, may or may not intersect thecenter or longitudinal axis 14. The cross-members 112 can be used toincrease the stiffness of the stiffening element 100. In otherimplementations, the cross-members can be form any shape that defines 2or more openings within the stiffening element.

Referring to FIGS. 11A through 11F, in other implementations thestiffening element 100 can have a generally disk shape. The shape andconstruction of the disk shape can vary. In the implementation of FIG.11A, the stiffening element 100 has a cup like shape or a petri-dishtype shape. Referring to FIGS. 11B and 11C, in other implementations,the stiffening element 100 can have a disk shape that resembles a puckor slug, in which the stiffening element 100 has a substantially solidcircular shape. The stiffening element 100 can vary in shape, color orconstruction. For example, in FIG. 11B, the stiffening element is formedof a polycarbonate material. In the implementation of FIG. 11C, thestiffening element can be include fiber reinforcement with apolycarbonate material or other polymeric material.

Referring to FIG. 11D, in one implementation, the stiffening element 100takes the form of a honeycomb disk with a honeycomb structure 120positioned on either side of a cross disk. Referring to FIG. 11E, thestiffening element 100 can be a pair of circular discs 114 separated byone or more spacing elements 116. Referring to FIG. 11F, the stiffeningelement 100 can be formed of two or more separate materials such as analuminum outer portion 122 and a polymeric inner portion 124. The outerportion 122 can be an annular member with a cross-sectional shapesimilar to the above-described annular members, and the inner portion124 can have a conical shape for facilitating some compression of thestiffening element 100. The shape, size and material construction of theinner and outer portions 124 and 122 can be varied to match a particularapplication or desired stiffness value.

FIGS. 12 and 13A illustrate other example implementations of the presentinvention in which the stiffening element 100 is shown positioned oneither side of the ABI fuse region 90 within the barrel portion 18 ofthe bat 10 or 200. As shown in FIGS. 12 and 13, the ABI fuse region 90can be positioned on either side of the stiffening element 100 dependingon a particular application or desired failure location. In FIGS. 12 and13A, the ABI fuse region 90 is shown longitudinally spaced apart fromthe stiffening element 100. In one implementation, the ABI fuse region90 can be longitudinally positioned with respect to the stiffeningelement 100 so as to within the range of 0 to 1.0 inch. In one exampleimplementation, the ABI fuse region 90 can be longitudinally positionedso as to overlie one of the edges of the stiffening element 100. Inanother example implementation, the ABI fuse region 90 can belongitudinally spaced apart from the stiffening element 100 by up to 1inch. In another implementation, the ABI fuse region 90 can belongitudinally positioned with respect to the stiffening element 100 soas to within the range of 0.1 to 0.75 inch.

FIG. 13B illustrates another example implementation of the presentinvention in which the ABI fuse region 90 within the barrel portion 18of the bat 10 or 200 overlies, or is positioned at the same longitudinallocation along the barrel portion 18, as the stiffening element 100. InFIG. 13B, the ABI fuse region 90 is shown positioned near the center ofthe stiffening element 100. However, the ABI fuse region 90 can also bepositioned at any location that overlies or is in the same longitudinallocation along the barrel portion as the stiffening element 100.

Referring to FIG. 14A, in another implementation, the stiffening element100 can be formed by creating a region of increased thickness in thecomposite lay-up of the bat barrel portion 18. The region of increasedthickness increases the stiffness of the barrel portion 18 at thatlocation thereby forming a stiffening element. The stiffening element100 of FIG. 14A is integrally formed with the barrel portion 18 of thebat 10. The stiffening element 100 can be formed as part of the originallay-up of the barrel portion 18 formed of fiber composite material oradded during or after the lay-up of the barrel portion 18 as part of aco-molding or secondary molding process. As shown in FIG. 14A, the ABIfuse region 90 can be positioned on either side of the stiffeningelement 100 depending on a particular application or desired failurelocation. FIG. 14A illustrates the ABI fuse region positioned in the batbarrel 18 to be on the end cap side of the stiffening element 100.However, the ABI fuse region 90 can also be placed on the handle side(or opposite side) of the stiffening element 100.

FIG. 14B illustrates another example implementation of the presentinvention in which the ABI fuse region 90 within the barrel portion 18of the bat 10 or 200 is positioned at the same longitudinal locationalong the barrel portion 18, as the stiffening element 100, wherein thestiffening element is formed by creating a region of increased thicknessin the composite lay-up of the bat barrel portion 18. In FIG. 14B, theABI fuse region 90 is shown positioned on the barrel portion 18 at alongitudinal location near the center of the stiffening element 100 (thecenter of the region of increased wall thickness of the barrel portion19). However, the ABI fuse region 90 can also be positioned at anylocation that is within the region of increased wall thickness along thebarrel portion 18.

Referring to FIG. 9, in one implementation, the bat 200 may include anABI fuse region 90 b positioned adjacent the endcap 38 of the bat 20.The endcap 38 can serve to increase the stiffness of the distal end ofthe barrel portion 18. In such a construction, the bat 200 may be formedwith or without a stiffening element 100. The endcap 38 essentiallyprovides a similar function as that of the stiffening element bycreating a sudden change in barrel stiffness that can force a failure orcatastrophic failure of the bat barrel portion 18 during the bat rollingprocedure of the ABI break-in test at the ABI fuse region 90 b.

Referring to FIG. 15, in another implementation of the presentinvention, an ABI fuse region 190 can be formed by adding a groove 192within the inner surface 30 of the barrel portion 18 formed of a fibercomposite material. In one implementation, the groove 192 is machinedinto the inner surface 30 of the barrel portion 18 after the barrelportion 18 has been laid-up and fully cured. In other implementations,the groove can be formed into the other inner surface of the barrelportion through other means such as molding. The groove 192 can be asingle continuous annular groove extending completely about the innercircumference of the barrel portion 18. The groove 192 is orientated soas to be generally perpendicular to the longitudinal axis 14. In otherwords, the groove 192 can extend about a groove plane 198 that isperpendicular to the longitudinal axis 14. The groove 192 can have adepth within the range of 5 to 75 percent of the wall thickness of thebarrel portion 18 at the general location of the groove 192. In otherimplementations, the groove 192 can have a depth within the range of 10to 50 percent of the wall thickness 18 of the barrel portion.

The groove 192 creates a fuse or a discontinuity in the barrel portion18 that forms the ABI fuse region 190. The groove 192 can have asemi-circular shape. In other implementations, the groove can have othershapes such as for example, semi-ovular, triangular, rectangular, otherpolygonal shapes and other curved shapes. When the bat 10 with the ABIfuse region 190 is subjected to an ABI break-in test including a batrolling procedure, the discontinuity caused by the groove 192 can resultin the bat barrel portion 18 failing or catastrophically failing duringthe bat rolling procedure of the ABI break-in test.

In one implementation, the ABI fuse region 190 can be spaced apart fromthe end cap 38 at the distal end of the barrel portion 18 by a distancewithin the range of 1.0 to 4.0 inches. In another implementation, theABI fuse region 190 can be spaced apart from the end cap 38 at thedistal end of the barrel portion 18 by a distance within the range of7.0 to 12.0 inches.

Referring to FIGS. 16 through 18, the ABI fuse region 190 can take avariety of different forms. In the implementation of FIG. 16, the ABIfuse region 190 is formed by two longitudinally spaced apart grooves 192a and 192 b. The grooves 192 a and 192 b can be formed in differentlengths and/or widths. The grooves, such as groove 192 a, include firstand second side edges 193 and 195 defined by the transition of thegroove to the barrel portion 18. The grooves, such as groove 192 a havea width, w, within the range of 0.25 to 4.0 inches, when measured fromthe first side edge 193 to the second side edge 195. In oneimplementation, the width w of the groove, such as the groove 192 a, canbe within the range of 0.025 to 0.5 inch. The grooves 192 a and 192 bcan be longitudinally spaced apart from each other by a distance withinthe range of 0.25 to 10.0 inches. In another implementation, the grooves192 a and 192 b can have the same width and/or depth. In otherimplementations, the number of grooves 192 formed in the barrel portion18 can be 3 or more.

Referring to FIG. 17, in another implementation, the groove 192 can beangled such that the groove 192 extends about a groove plane 198 that isangled with respect to the longitudinal axis 14 within the range of 45to 89 degrees. Referring to FIG. 18, in another implementation, the ABIfuse region 190 can be formed by a spiral groove 190 formed within theinner surface 30 of the barrel portion 18. The spiral groove 190 can beangled with respect to the longitudinal axis 14 of the bat 10 such thatthe spiral groove 190 extends about the entire circumference of thebarrel portion 18 within a longitudinal distance of 13 inches or lesswhen measured with respect to the longitudinal axis 14. In otherimplementations, the spiral groove 190 can be angled such that thelongitudinal distance required for the spiral groove to extend about thecircumference of the barrel portion 18 is 7 inches or less. In anotherimplementation, the spiral groove 190 may extend about the barrelportion 18 in a manner such that the spiral groove 190 extends over lessthan a full circumference of the barrel portion 18. In otherimplementations, other orientations, sizes, numbers and shapes ofgrooves can be used to form the ABI fuse region.

Referring to FIG. 19, in one implementation, the ABI fuse region 190 canbe formed adjacent to the ABI fuse region 90. The ABI fuse region 190can be longitudinally spaced part from the ABI fuse region 90 by adistance of at least 0.25 inch.

Referring to FIGS. 20A and 21B, in other implementations the ABI fuseregion 190 can be positioned adjacent the stiffening element 100. Thegroove 192 can be positioned on either side of the stiffening element100 within the bat barrel 18. In FIG. 20A, the stiffening 100 is a discinserted within the barrel portion 18, and in FIG. 21A, the stiffeningelement 100 is formed by a region of increased wall thickness of thebarrel portion 18 of the bat 10.

Referring to FIGS. 20B and 21B, in other implementations the ABI fuseregion 190 can be positioned or located to be at substantially the samelongitudinal location about the barrel portion 18 as the stiffeningelement 100. In FIG. 20B, the stiffening 100 is a disc inserted withinthe barrel portion 18, and in FIG. 21B, the stiffening element 100 isformed by a region of increased wall thickness of the barrel portion 18of the bat 10. The ABI fuse region 190 can be formed by placing thegroove 190 at any longitudinal location along the barrel portion 18 thatis aligned with the stiffening element 100. In one implementation, theABI fuse region 190 can be positioned longitudinally along the barrelportion 18 such that it overlies the stiffening element 100.

The bat 10, 200 of the present invention provides numerous advantagesover existing ball bats. One such advantage is that the bat 10, 200 ofthe present invention is configured for competitive, organized baseballor softball. For example, embodiments of ball bats built in accordancewith the present invention can fully meet the bat standards and/orrequirements of one or more of the following baseball and softballorganizations: ASA Bat Testing and Certification Program Requirements;United States Specialty Sports Association (“USSSA”) Bat PerformanceStandards for baseball and softball; International Softball Federation(“ISF”) Bat Certification Standards; National Softball Association(“NSA”) Bat Standards; Independent Softball Association (“ISA”) BatRequirements; Ball Exit Speed Ratio (“BESR”) Certification Requirementsof the National Federation of State High School Associations (“NFHS”);Little League Baseball Bat Equipment Evaluation Requirements; PONYBaseball/Softball Bat Requirements; Babe Ruth League Baseball BatRequirements; American Amateur Baseball Congress (“AABC”) Baseball BatRequirements; and, especially, the NCAA BBCOR Standard or Protocol.

Accordingly, the term “bat configured for organized, competitive play”refers to a bat that fully meets the ball bat standards and/orrequirements of, and is fully functional for play in, one or more of theabove listed organizations.

The present invention provides a method and system for forming barrelportions of a ball bat or other cylindrical portions of a ball bat usingfiber composite material that can satisfy ball bat equipment standardsand/or requirements in a cost effective, reliable and high qualitymanner. The present invention provides a method and system for formingbarrel portions of a ball bat or other cylindrical portions of a ballbat using fiber composite material that provides a high quality cosmeticappearance, is highly durable, and provides the desired operationalcharacteristics. The present invention provides a method and system forforming barrel portions of a ball bat or other cylindrical portions of aball bat using fiber composite material that can satisfy performancerequirements, such as BBCOR certification or the USABat standard,without adding too much weight or wall thickness to the barrel portion.The present invention also provides a ball bat with a desirable level ofbarrel stiffness, exceptional feel and performance.

While the preferred embodiments of the invention have been illustratedand described, it will be appreciated that various changes can be madetherein without departing from the spirit and scope of the invention.One of skill in the art will understand that the invention may also bepracticed without many of the details described above. Accordingly, itwill be intended to include all such alternatives, modifications andvariations set forth within the spirit and scope of the appended claims.Further, some well-known structures or functions may not be shown ordescribed in detail because such structures or functions would be knownto one skilled in the art. Unless a term is specifically defined in thisspecification, the terminology used in the present specification isintended to be interpreted in its broadest reasonable manner, eventhough may be used conjunction with the description of certain specificembodiments of the present invention

1. A ball bat extending along a longitudinal axis and configured fortesting under an accelerated break-in test, the bat comprising: a barrelportion including a proximal region and a distal region, the barrelportion being formed of a fiber composite material having wall thicknessof at least 0.060 inch, the fiber composite material including at leastfirst and second plies, the first ply including a first plurality offibers aligned adjacent to one another and a first resin, and the secondply including a second plurality of fibers aligned adjacent to oneanother and a second resin, the first ply including a first fiberdiscontinuity and the second ply including a second fiber discontinuity,the first and second fiber discontinuities being generally aligned witheach other such that one of the first and second fiber discontinuitiessubstantially overlies the other of the first and second fiberdiscontinuities creating an ABI fuse region of the barrel portion, theABI fuse region forming a crack initiation location when the bat issubjected to the accelerated break-in test, each of the first and seconddiscontinuities forming first and second spaces between the first andsecond pluralities of fibers, respectively, one or both of the first andsecond resins filling the first and second spaces.
 2. The ball bat ofclaim 1, wherein the at least first and second plies includes at leastthe first ply, the second ply and a third ply, wherein the third plyincludes a third fiber discontinuity, and wherein the third fiberdiscontinuity is generally aligned with the first and second fiberdiscontinuities such that one or both of the first and seconddiscontinuities substantially overlie the third discontinuity or thethird discontinuity substantially overlies one or both of the first andsecond discontinuities.
 3. The ball bat of claim 2, wherein the at leastfirst and second plies includes at least the first ply, the second ply,the third ply and a fourth ply, wherein the fourth ply includes a fourthfiber discontinuity, and wherein the fourth fiber discontinuity isgenerally aligned with the first, second and third fiber discontinuitiessuch that one or more of the first, second and third discontinuitiessubstantially overlie the fourth discontinuity or the fourthdiscontinuity substantially overlies one or more of the first, secondand third discontinuities.
 4. The ball bat of claim 1, wherein the firstand second fiber discontinuities extend about a discontinuity plane. 5.The ball bat of claim 4, wherein the discontinuity plane is angled withrespect to the longitudinal axis by an angular amount within a range of45 to degrees.
 6. The ball bat of claim 4, wherein the discontinuityplane is substantially perpendicular to the longitudinal axis.
 7. Theball bat of claim 1, wherein the first and second fiber discontinuitiesdefine a curved line radially spaced from the longitudinal axis.
 8. Theball bat of claim 7, wherein the curved line is a spiral line.
 9. Theball bat of claim 8, wherein the curved line extends about a portion ofa circumference of the barrel portion within a longitudinal dimension of13 inches or less.
 10. The ball bat of claim 1, further comprising astiffening element positioned within the barrel portion and adjacent theABI fuse region.
 11. The ball bat of claim 10, wherein the stiffeningelement is an annular member.
 12. The ball bat of claim 10, wherein thestiffening element is a circular disc.
 13. The ball bat of claim 10,wherein the stiffening element is longitudinally spaced apart from theABI fuse region by a distance within the range of 0.0 inch to 1.0 inch.14. The ball bat of claim 10, wherein the stiffening element islongitudinally spaced apart from the ABI fuse region by a distancewithin the range of 0.1 to 0.75 inch.
 15. The ball bat of claim 10,wherein the stiffening element is formed of a rigid material selectedfrom group consisting of aluminum, polycarbonate, polyurethane,titanium, other metals, other polymeric materials and combinationsthereof.
 16. The ball bat of claim 1, wherein at least one of the firstand second fiber discontinuities is a plurality of segmented cutsgenerally defining a curved dashed line radially spaced from thelongitudinal axis.
 17. The ball bat of claim 1, wherein the first andsecond plies have first and second ply thicknesses, respectively, andwherein at least one of the first and second fiber discontinuities is acut extending through at least 50% of one of the first ply thickness andthe second ply thickness.
 18. The ball bat of claim 17, wherein at leastone of the first and second fiber discontinuities is a cut extendingthrough at least 75% of the thickness of at least one of the first andsecond plies.
 19. The ball bat of claim 1, wherein one of the first andsecond fiber discontinuities directly overlies the other of the firstand second fiber discontinuities.
 20. The ball bat of claim 1, whereinthe one of the first and second fiber discontinuities substantiallyoverlies the other of the first and second fiber discontinuities suchthat a longitudinal dimension between the first and seconddiscontinuities can be within the range of 0.0 to 0.2 inch.
 21. The ballbat of claim 20, wherein the longitudinal dimension between the firstand second discontinuities can be within the range of 0.0 to 0.1 inch.22. The ball bat of claim 1, wherein the first ply includes a firstproximal ply portion and a first distal ply portion, and wherein thefirst fiber discontinuity separates the first proximal ply portion fromthe first distal ply portion.
 23. The ball bat of claim 22, wherein thefirst plurality of fibers of the first proximal ply portion aregenerally aligned to define first proximal angle with respect to thelongitudinal axis, wherein the first plurality of fibers of the firstdistal ply portion are generally aligned to define first distal anglewith respect to the longitudinal axis, and wherein the first proximalangle and the first distal angle vary by at least 10 degrees.
 24. Theball bat of claim 22, wherein the first proximal angle and the firstdistal angle vary by at least 30 degrees.
 25. The ball bat of claim 10,wherein the stiffening element is longitudinally positioned within thebarrel portion such that the ABI fuse region overlies the stiffeningelement.